RFID Tag Punching Alignment for High-Volume Sheet Production
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Solution Overview
Problem
There is a need for a manufacturing system capable of mass-producing sheet-like RFID tags efficiently, as existing methods are inadequate for large-scale production.
Innovation Solution
The system includes a conveyance device for base sheets with RFIC modules, a laminating device for attaching a cover seal, and a punching device with a frame-shaped cutting edge to form RFID tags by punching the cover seal and base sheet, utilizing alignment marks for precise positioning and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional manufacturing method is used for RFID tags, then individual tags can be produced, but mass production efficiency is insufficient
Solution Approach 1:
The base sheet is divided into multiple antenna patterns arranged in a matrix, allowing simultaneous processing of multiple tags. The punching blade is segmented into multiple cutting edges that can punch multiple tags in one operation, enabling mass production while maintaining individual tag quality
Solution Approach 2:
Multiple antenna patterns are arranged on a single base sheet and processed together through the laminating and punching operations. The system combines multiple tagging operations into a single production cycle, dramatically improving productivity while the automated positioning system maintains manufacturing precision
2Reliability
If the cover seal is attached to cover the antenna patterns, then the RFIC modules are protected, but positioning accuracy becomes challenging
Solution Approach 1:
An alignment mark is introduced as an intermediary reference element on the base sheet. The punching device detects this mark to determine the precise position of antenna patterns, enabling accurate positioning even when the cover seal obscures the antenna patterns. This intermediary reference solves the positioning problem without compromising protection
Solution Approach 2:
The alignment mark is pre-positioned on the base sheet before the cover seal is attached. This preliminary placement of a reference marker allows the punching device to calculate and compensate for any positioning deviations, ensuring accurate punching positions while maintaining the protective cover seal configuration
3Productivity
If multiple antenna patterns are arranged on a base sheet, then mass production is enabled, but the complexity of the manufacturing system increases
Solution Approach 1:
The punching blade is designed with multiple cutting edges that can simultaneously punch multiple tags in one operation. The conveyance device and punching device work together as a multi-functional system that handles both transportation and precise positioning in an integrated manner, reducing the need for separate processing stations and simplifying the overall manufacturing system
Solution Approach 2:
The punching device automatically detects the alignment mark and calculates the positions of multiple antenna patterns without requiring external intervention for each tag. The system self-adjusts and self-positions for each punching operation, reducing the need for complex manual positioning mechanisms and simplifying system operation
Data Source
AI summary
An RFID tag manufacturing system is provided that includes a conveyance device that conveys a base sheet provided with a plurality of antenna patterns to each of which an RFIC module is fixed. The system includes a laminating device that attaches a cover seal on the base sheet to cover the antenna patterns and a punching device that produces RFID tags by punching the cover seal and the base sheet with a punching blade that includes a frame-shaped cutting edge surrounding the antenna patterns to form a frame-shaped cut. The base sheet includes alignment mark in a non-attachment part of the cover seal. The punching device specifies the position of each of the antenna patterns covered with the cover seal based on the alignment mark, and punches the cover seal and the base sheet based on the specified position of the antenna pattern.